KR20190016101A - Photovoltaic module with external electrical connector - Google Patents

Abstract

A photovoltaic module having an external electrical connector is described. For example, the photovoltaic module may include a plug receptacle mounted on the module laminate, and the contacts may extend from the photocell in the module laminate into the plug channel of the plug receptacle. The plug receptacle may receive a mating electrical connector (e.g., an electrical plug) of the panel outer electronics. Thus, the contacts can be removably connected to the mating electrical connector, and the photovoltaic cells can be electrically connected to the panel external electronics.

Description

Photovoltaic module with external electrical connector

This patent application claims the benefit of priority to U.S. Provisional Patent Application No. 15 / 201,064, filed July 1, 2016, the entirety of which is incorporated herein by reference.

A photovoltaic cell (PV), commonly known as a solar cell, is a well-known device for directly converting solar radiation into electrical energy. Generally, solar cells are fabricated on semiconductor wafers or substrates using semiconductor processing techniques to form p-n junctions near the surface of the substrate. The solar radiation impinging on the surface of the substrate produces electron and hole pairs in the majority of the substrate and creates a voltage difference between the doped regions by moving to the p-doped and n-doped regions of the substrate. The doped regions are connected to metal contacts on the solar cell to direct current from the cell to an external circuit coupled to the cell. Generally, solar cell arrays in which each solar cell is interconnected are mounted on a common or shared platform to provide a photovoltaic module. The photovoltaic module may comprise a photovoltaic laminate. A plurality of photovoltaic modules or groups of modules may be electrically coupled to a power distribution network forming the photovoltaic system.

1 illustrates a perspective view of a photovoltaic system having a photovoltaic module electrically connected to a panel external electronic device via an external cable in accordance with one embodiment of the present disclosure.
2 illustrates a perspective view of an intra-panel module circuit of a photovoltaic module according to one embodiment of the present application.
3 illustrates a partial cross-sectional perspective view of an external electrical connector of a photovoltaic module in accordance with one embodiment of the present disclosure.
4 illustrates a top view of an external electrical connector of a photovoltaic module according to one embodiment of the present disclosure.
5 illustrates a top view of a contact terminal of a contact portion extending through a contact slot of a plug receptacle according to one embodiment of the present application.
6 illustrates an exploded view of an external electrical connector of a photovoltaic module according to one embodiment of the present disclosure;
7 illustrates a cross-sectional view of a module laminate-shaped plug receptacle in accordance with one embodiment of the present invention.
8 illustrates a perspective view of a module frame having a module laminate-shaped plug receptacle according to one embodiment of the present disclosure.
Figure 9 illustrates a perspective view of a contact mounted to the side edges of a module laminate in accordance with one embodiment of the present disclosure.
10 illustrates a cross-sectional view of a module frame having a plug receptacle mounted on a module laminate in accordance with one embodiment of the present disclosure;
11 illustrates a cross-sectional view of a plug receptacle having a mount casing attached to a module laminate in accordance with one embodiment of the present disclosure.
12 illustrates a flow diagram of a method of manufacturing a photovoltaic module having an external electrical connector, in accordance with one embodiment of the present disclosure.
13 illustrates a cross-sectional perspective view of an external electrical connector of a photovoltaic module in accordance with one embodiment of the present disclosure.

The following detailed description is merely exemplary in nature and is not intended to limit the scope of the present invention or the embodiments of the present application and uses of such embodiments. As used herein, the word "exemplary" means "serving as an example, instance, or illustration. &Quot; Any embodiment described herein as illustrative is not necessarily to be construed as preferred or advantageous over other embodiments. Further, the present invention is not intended to be limited to the above-described technical field, background art, contents of the invention, or any explicit or implied theory presented in the detailed description for carrying out the invention described below.

The specification includes references to "one embodiment" or "one embodiment ". The appearances of "in one embodiment" or "in one embodiment" are not necessarily referring to the same embodiment. Certain features, structures, or characteristics may be combined in any suitable manner consistent with the present invention.

Terms. The following paragraphs provide definitions and / or relationships for terms found in this disclosure (including the appended claims): < RTI ID = 0.0 >

"Containing". This term is open-ended. As used in the appended claims, this term does not exclude additional structures or steps.

The various units or components configured to " comprise " or " configured to " In this context, "configured to" is used to imply a structure by indicating that the unit / component includes structures that perform these tasks or tasks during operation. As such, a unit / component may be said to be configured to perform an operation even when the specified unit / component is not currently operating (e.g., even when it is not in an on / active state). Reference to a unit / circuit / component being "configured to" perform one or more tasks is intended to not explicitly apply the sixth paragraph of 35 USC § 112 to that unit / component.

"First", "Second" and so on. As used herein, these terms are used as markers for the following nouns, and do not imply any ordering of any type (e.g., spatial, temporal, logical, etc.). For example, reference to a " first "direction does not necessarily imply that this direction is first in turn, but instead the term" first " . ≪ / RTI >

"Combined" - the following description refers to elements or nodes or features that are "coupled " together. As used herein, unless expressly stated otherwise, "coupled" need not be mechanical, but it is understood that one element / node / feature may be directly or indirectly coupled Directly or indirectly) with the other.

It is also to be understood that the particular terminology may be used in the following description for purposes of illustration only, and thus is not intended to be limiting. For example, terms such as "upper," "lower," "upper," "lower," "front," and "back" refer to directions in the referenced drawings. The terms such as "front," " back, "" rear," " lateral, "" Describes the relative orientation and / or location of components or a component within a consistent but arbitrary coordinate system. These terms may include words specifically mentioned above, derivatives thereof and words of similar meaning.

" Suppress" - as used herein, is used to describe reducing or minimizing the effect of inhibition. When a component or feature is described as suppressing an additive action, action, or condition, it can completely prevent a result or outcome or future condition. Also, "inhibition" may mean reduction or mitigation of the result, performance and / or effect that may otherwise occur. Thus, where a component, element or feature is referred to as suppressing an outcome or condition, it is not necessary to completely prevent or eliminate the outcome or condition.

PV cells can be assembled with PV strings inside PV modules that can be used to convert sunlight into electricity. Electricity is generally transferred from the module circuit, i. E. The PV string, to the panel-mounted electronics of the PV system. In particular, the on-panel electronic device generally includes electronic components such as a junction box attached to the back sheet of the PV module or a diode, microinverter or DC optimizer housed in a PV dock. The junction box or PV dock is typically secured to the backing sheet by a silicon-based adhesive after the PV module is fully formed by the lamination process. An electrical ribbon, or thin and flexible metal strip, is attached to the module circuit inside the PV module during the lamination process and then routed through the manual cutting slit of the backing sheet to carry the current into the attached junction box.

In the above description, a conventional photovoltaic (PV) module includes a thin and flexible electrical ribbon extending from the module circuit in the panel to the on-panel electronics through the back sheet of the PV module. The direct connection between the module circuit in the panel and the on-panel electronic device may be convenient in that a variety of junction boxes can be secured to the PV module to provide different functions, but the on-panel electronic device lacks component interchangeability . That is, once the electronic device on the panel is attached, it can not be removed or replaced. Also, routing the electrical ribbon from the module circuit in the panel to the electronics on the panel requires manual finesse and is not easy to automate, resulting in increased manufacturing time and cost. Thus, by providing a PV module with an external electrical connector, the PV module can be easily and interchangeably connected to the panel's external electronics so that the PV module can improve PV system flexibility and manufacturing efficiency.

In one aspect, a PV module with an external electrical connector is provided. In particular, the external electrical connector may include a contact, such as a metal blade-type connector, permanently bonded to an electrical conductor within the PV module laminate, e.g., a bus bar or an electrical ribbon, And extend outwardly through the receptacle. The plug receptacle can provide electrical and environmental protection to the contacts, accommodate mating electrical connectors such as plugs, and mechanically support the miter when the mating electrical connector engages the external electrical connector. Thus, the module circuit in the panel can be electrically connected to the matching electrical connector via the contact or to the panel external electronics connected to the external cable or matching electrical connector.

The above-described features can be realized by a PV module having an external electrical connector as disclosed herein. In the following description, numerous specific details are set forth, such as specific material regimes and component structures, to provide a thorough understanding of the embodiments of the present disclosure. It will be apparent to those skilled in the art that the embodiments herein may be practiced without these specific details. In other instances, well-known manufacturing techniques or component structures, such as electrical connectors or specific types of module lamination processes, are not described in detail so as not to unnecessarily obscure the embodiments of the present disclosure. It is also to be understood that the various embodiments shown in the drawings are exemplary and are not necessarily drawn to scale.

In summary, PV systems and modules with external electrical connectors are disclosed herein. In one embodiment, the PV system includes a PV module electrically connected to the panel external electronics by an external cable. The PV module may comprise a module laminate having an electrical conductor electrically connected to the PV cell. The contacts can be attached to the electrical conductor and extend into the plug channel of the plug receptacle mounted on the module laminate. So that the contacts can transfer current from the PV cell into the plug receptacle. The plug receptacle may be connected to the panel external electronics to deliver current to the device.

In one embodiment, the contacts may include a contact base that is laminated between the front layer and the back layer of the modular laminate by the enclosing protective agent. The plug receptacle can be bonded to the module laminate by an adhesive, and in one embodiment, the protective agent and the adhesive are the same material and are cured during the same lamination process. The plug receptacle can be mounted at a different location on the module laminate. For example, the plug receptacle can be glued along the back surface of the PV module or along the side edge of the PV module. In one embodiment, the one or more plug receptacles are integrated into a module frame that can be attached to the side edge of the PV module to form an external electrical connector for each of the multiple substrings of the PV cell of the PV module.

In summary, a method of manufacturing a PV module having an external electrical connector is also disclosed herein. In one embodiment, the method comprises physically and / or electrically connecting the contact between the front layer and the back layer of the PV cell, the electrical conductor and the PV module. For example, the contacts may include contact bases between the front and back layers and contact terminals that extend outwardly from the module laminate. During the lamination process, the PV cells, electrical conductors, and contacts may be surrounded by a protective agent, which may cure and bond the components together in a solidified module laminate. The contact terminals may extend outward from the solidified module laminate. The plug receptacle is thus mounted on the module laminate so that the contact terminals extend into the plug channel of the plug receptacle through the contact slot of the plug receptacle. A mating connector, for example, an external cable or a connector of the panel external electronic device, may be received within the plug channel for electrical connection to the contact terminal for power delivery.

Referring to Figure 1, a perspective view of a PV system having a PV module electrically connected to an external panel electronics through an external cable is shown in accordance with one embodiment of the present disclosure. The PV system 100 may include a PV module 102 electrically connected to the panel external electronics 104 by an external cable 106. In particular, the outer cable 106 may extend from the outer electrical connector (FIG. 3) of the PV module 102 to the panel outerelectronic device 104. The external cable 106 may have a mating connector for quickly connecting and disconnecting to the PV module 102 and / or the panel external electronics 104. The external electrical connector may include a male or female electrical connector, as described below, and the mating connector may have a corresponding male or female connector to form a male-female connection.

The panel external electronic device 104 can be easily removed from the PV system 100 and replaced. By way of example, the panel external electronics 104 may include one or more bypass diodes, microinverters, or DC optimizers. Thus, when the bypass diode fails or the microinverter or DC optimizer is upgraded, the device can be replaced. Similarly, it can be easily added by connecting new and different module electronics to external cable 106. Thus, the PV system 100 is component compatible.

In one embodiment, the PV module 102 includes one or more cell rows 112 and a module laminate 108 having several PV cells 110 arranged in a cell column 114. For example, the module laminate 108 may comprise a string of PV cells 110 electrically connected in series, as is known. The string of PV cells 110 may be divided physically in parallel into substrings 116, which may include PV cells 110 arranged in an electrical series. That is, each sub-string includes a second cell row 112 adjacent to the first cell row 112 in a second direction in which the current flows in a first direction through the first cell row 112 and the current is opposite the first direction, And may be electrically connected in series with adjacent substrings 116 to flow therethrough. As described below, in one embodiment, the first substring 116 may be connected to an adjacent substring 116 via an external cable 106.

2, there is shown a perspective view of an in-panel module circuit of a PV module according to an embodiment of the present invention. The module laminate 108 of the PV module 102 may include a front layer 202, e.g., a glass panel, parallel to and spaced from the backing layer 204, such as, for example, a polymer sheet. The module laminate 108 may comprise a parallel flat sheet having the same edge so that the module laminate 108 has a side edge 206 extending around the outer periphery of the PV module 102.

The PV module 102 may include a bus bar and / or an electrical conductor 208, e.g., an electrical ribbon, to transfer current away from the PV cell 110. [ In particular, the electrical conductor 208 may be connected to the corresponding PV cell 110, for example, by welding or solder bonding between the front layer 202 and the backside layer 204. For example, the electrical conductor 208 may be electrically connected to one or more PV cells 110 closest to the side edge 206. Thus, the electrical conductor 208 can deliver the current generated by the corresponding PV cell 110. In one embodiment, electrical conductor 208 transfers the current generated by one or more substrings 116 of PV module 102 to a corresponding external electrical connector, such as a following connector.

3, there is shown a partial cross-sectional perspective view of an external electrical connector of a PV module according to an embodiment of the invention. The external electrical connector 300 may be mounted on the front layer 202 or back layer 204 of the module laminate 108. The external electrical connector 300 may include a plug receptacle 302 and in one embodiment the plug receptacle 302 is attached to the back surface 304 of the backing layer 204 on the module laminate 108 . The plug receptacle 302 may provide a universal connector for attachment to the outer cable 106 and the panel outer electronics 104 (Figure 1) 306). In the following description, the plug casing 306 surrounds the contacts 308 and the base 310 of the plug casing 306 may be bonded or sealed to the back surface 304. The plug casing 306 thus provides electricity to the PV system 100 by preventing water inflow to the contacts 308 or module circuitry within the panel when the external electrical connector 300 is connected to the mating connector of the external cable 106 While protecting the environment.

4, a top view of an external electrical connector of a PV module according to an embodiment of the invention is shown. In one embodiment, the mating connector of the outer cable 106 (Fig. 1) may be received within the plug channel 402 of the plug casing 306. [ In particular, the plug casing 306 may include a casing wall 404 that laterally extends about a central axis to define a plug channel 402. The casing wall 404 forms a plug channel 402 having any type of path, for example, a circular path or a substantially rectangular path as shown in Fig. 4 and having a cross-sectional area coinciding with the cross-sectional area of the mating connector . That is, the plug casing 306 may include cylindrical walls, rectangular walls, and the like, having an interior surface that receives the exterior surface of the mating connector in a sliding fit. The casing wall 404 may extend up to a height above the base wall 406. The base wall 406 may be part of the base 310 below the plug casing 306. Thus, the base wall 406 may be perpendicular to the lower end central axis of the plug channel 402.

The base wall 406 may have a contact slot 408 aligned with the plug channel 402. For example, the contact slot 408 may be an opening formed through the base wall 406 facing the plug channel 402 to the base wall 406 facing the back surface 304. The contact slot 408 may be coaxially aligned with the plug channel 402 along the central axis as shown, or the contact slot 408 may be non-coaxial but inwardly oriented with the plug channel 402. The contact portion 308 may extend from the casing wall 404 through the contact slot 408 to the plug channel 402 at a laterally inward position.

5, there is shown a top view of the contact terminal of the contact portion extending through the contact slot of the plug receptacle according to one embodiment of the present application. The contact slot 408 in the base wall 406 of the plug receptacle 302 can be sized to support the contact portion 308 against side bending. The contact portion 308 may include a contact portion terminal 502 extending into the plug channel 402 through the contact portion slot 408 and the contact portion terminal 502 may include a contact portion (406) may be sized similar to the contact slot (408) to enhance the thermal strength of the contact terminal (502). Thus, the contact terminal 502 may include a profile about the axis of the contact cross-sectional area 504, i.e., the axis passing through the contact terminal 502, and the contact slot 408 may include a similarly sized slot cross-sectional area 506, And may include a profile about the axis and contact cross-sectional area 504. That is, the slot cross-sectional area 506 may coincide with the contact cross-sectional area 504. For example, the lateral dimension across the contact width 508, that is, the contact cross-sectional area 504, may be similar to the lateral dimension across the slot width 510, i.e., the slot cross-sectional area 506. The contact width 508 can be pre-selected to provide a desired stiffness to the contact terminal 502. In one embodiment, the contact width 508 is at least 75% of the slot width 510. Thus, the contact cross-sectional area 504 may be less than the slot cross-sectional area 506, and there may be a gap between the base wall 406 and the contact terminal 502. The gap can be optimized to allow the plug casing 306 to be easily inserted over the contact terminal 502 and to support the contact terminal 502 laterally when the mating connector is connected to the external electrical connector 300.

It will be appreciated that the contact portion terminal 502 of the contact portion 308 may be a male or female contact. In some embodiments, however, contact terminal 502 is shown as a female receptacle contact, e.g., an outer cable 106 (not shown), for example, (Fig. 1) of the mating connector. Modifications of such contact designs will be apparent to those skilled in the art. For example, it is understood that the contacts 308 may comprise a base material such as CuSn4 or CuFe2 coated with a plating, for example, tin, silver or gold. Therefore, a detailed description of the details has been omitted for the sake of brevity. The contact terminal 502 may extend through the contact slot 408 and be supported by the base wall 406 regardless of whether the contact terminal 502 is a male or female contact.

Referring to Figure 6, an exploded view of an external electrical connector of a PV module according to one embodiment of the present application is shown. The contact terminal 502, for example, the male contact tab may extend at right angles to the contact base 602 of the contact 308. [ For example, contact portion 308 may be T-shaped such that contact base portion 602 forms a T-shaped horizontal bar and contact portion terminal 502 forms a T-shaped vertical bar. The contact portion base 602 may be parallel to the back surface 304 of the module laminate 108 and the contact portion terminal 502 may extend perpendicularly to the back surface 304 along the contact portion axis 604. [ In particular, the contact axis 604 aligns with the contact slot 408 to allow the plug receptacle 302 to be placed on the contact 308 and on the back surface 304.

In one embodiment, a backsheet opening 606 may be formed in the backside layer 204 of the module laminate 108 over the electrical conductor 208. The electrical conductor 208 may extend along the conductor axis 608, for example, in a direction perpendicular to the contact axis 604. Thus, the contact terminal 502 may have terminal rigidity with respect to the contact axis 604, and the electrical conductor 208 may have a conductor stiffness with respect to the conductor axis 608. The exposed portion of the module circuitry in the panel, e.g., the contact portion 308, is in contact with the module laminate < RTI ID = 0.0 > May have greater rigidity than a portion of the module circuit in the panel, e. G., The electrical conductor 208, inside the module 108. More specifically, the terminal stiffness can be greater than the conductor stiffness. Also, in the above description, the contact terminal 502 can be supported by the base wall 406, so that the thermal strength of the contact terminal 502 can be substantially greater than the thermal strength of the electrical conductor 208.

The backsheet opening 606 may have a profile that is larger than the profile of the abutment base 602. For example, the back sheet opening 606 can be a rectangular hole formed through the backing layer 204 above the electrical conductor 208, and the rectangular hole can have a width and a length. The contact base 602 may have a rectangular or other type of profile including a width and length less than the width and length of the rectangular hole passing through the backing layer 204. [ The contact portion 308 can be inserted onto the electrical conductor 208 through the back sheet opening 606. [

In one embodiment, the back sheet openings 606 are formed in the backing layer 204 using an automated process. For example, the back sheet opening 606 may be a hole punched in the backing layer 204 using a punching press. So that the back sheet opening 606 can be a highly repeatable hole at any location in the backing layer 204. Routing of the contacts 308 through the backsheet opening 606 is easier and less costly to perform than routing the electrical ribbon through the manual slit passage in the back sheet of the PV module.

Referring to Figure 7, a cross-sectional view of a plug receptacle mounted on a module laminate in accordance with one embodiment of the present application is shown. The contact base portion 602 may be attached to the electrical conductor 208 when the contact portion 308 is inserted through the back sheet opening 606 of the backside layer 204. [ For example, the contacts 308 may have an L-shape and the L-shaped horizontal bar may be permanently attached to a portion of the exposed electrical conductor 208 through the back sheet opening 606, e.g., Can be soldered. Alternatively, the physical connection between the contact base portion 602 and the electrical conductor 208 may be formed by pressing the components together and sealing adjacent components as described below. Thus, the contact portion 308 can be electrically connected to the electrical conductor 208. The contact terminal 502 may be an L-shaped vertical bar and extend outwardly through the back sheet opening 606 of the backing layer 204 from the electrical conductor 208. Thus, the contact terminal 502 can provide an external contact point to interface with the matching connector of the external cable 106 (Fig. 1).

In one embodiment, at least a portion of the contacts 308 may be enclosed within the module laminate 108. For example, the protective agent 702 used to seal the PV cell 110 between the front and back layers 202 and 204 may also include a contact base 602 between the front and back layers 202 and 204, And electrical conductors 208, as shown in FIG. In particular, the protective agent 702 may fill the space between the PV cell 110 and the backside layer 204 where the contact base portion 602 is located. Thus, the protective agent 702 may adhere the contact portion 308 to the remaining module laminate 108 during the same lamination process used to form the module laminate 108.

The plug receptacle 302 may also be glued to the module laminate 108. For example, plug receptacle 302 may be formed in contact portion 308 such that contact terminal 502 extends into plug channel 402 and the upper surface of base 310 faces back surface 304 of backing layer 204, Lt; / RTI > That is, the plug receptacle 302 may be mounted on the back surface 304 of the backing layer 204. In one embodiment, an adhesive 704 is disposed between the plug receptacle 302 and the module laminate 108. The adhesive 704 may form an adhesive bond between the base 310 and the backing layer 204 to adhere the plug receptacle 302 to the module laminate 108. For example, The adhesive 704 may comprise a thermoset adhesive or a photo-curable material. For example, the adhesive 704 may be a thermosetting material the same as the protective agent 702, for example a thermoplastic olefin such as polyethylene. Alternatively, the adhesive 704 may be a UV curable adhesive, and the plug receptacle 302 may be formed of a transmissive material such that ultraviolet light can be transmitted through the adhesive 704 during the curing operation. The plug receptacle 302 may thus be permanently bonded to the backing layer 204 during the same or different operations as the lamination process used to form the module laminate 108. As a result, the external electrical connector 300 may be constructed directly into the PV module 102 such that the external cable 106 and / or the panel external electronics 104 (Figure 1) from the PV cell 110 of the PV module 102, To the external connection point.

Referring to Figure 8, there is shown a perspective view of a module frame with a plug receptacle mounted on a module laminate in accordance with one embodiment of the present disclosure. The external electrical connector 300 has been described above in the context of a connector that draws current into an external connection point through the backside layer 204 of the module laminate 108. However, the external electrical connector 300 may draw current from the PV cell 110 in any direction. In one embodiment, the one or more plug receptacles 302 are mounted on the side edges 206 (hidden) of the module laminate 108. For example, the PV system 100 includes a module frame 802 mounted along the side edge 206 of the module laminate 108 to support the PV module 102 at an installation site, for example, can do. The module frame 802 may include a plurality of plug receptacles 302. That is, the plug receptacle 302 may be integrally formed with the module frame 802, for example, during a frame molding or casting process.

The plug receptacle 302 mounted along the side edge 206 may be aligned with the respective PV cell row 112 or row 114. For example, the module laminate 108 includes a first substring 116 of PV cells aligned along a first cell row 112A and a second substring 116 of PV cells aligned along a second cell row 112B. (Not shown). The first plug receptacle 302 receives a first contact 308 that is aligned with the first cell row 112A and is electrically connected to the first cell row 112A and the second plug receptacle 302 receives the first contact 308, And a second contact portion 308 electrically connected to the second cell row 112B in alignment with the second cell row 112B. As such, the cell rows 112A and 112B may be electrically parallel because the corresponding contacts 308 may not be electrically connected, rather than electrically connected in a conventional manner. Thus, an electrical connection may be formed between the cell rows 112 by the external cable 106 and / or the panel external electronics 104 (FIG. 1). For example, the outer cable 106 may include a mating connector at each of the two ends, and the mating connector may be coupled to a respective plug receptacle 302 to electrically couple the substrings 116 in series. have. Alternatively, the matching connector may be coupled to a respective plug receptacle 302 of a number of substrings 116, and a bypass diode may be provided to allow current to flow through the bypass diode when the substring 116 is shut down. And may be electrically connected in series with the outer cable 106 to place the bypass diode in parallel with one or more substrings.

Referring to Fig. 9, there is shown a perspective view of the contacts mounted on the side edges of the module laminate in accordance with one embodiment of the invention. The contact portion 308 can be mounted along the side edge 206 of the PV module 102. In particular, the contact base 602 may have a clip structure, for example, a U-shaped cross-sectional structure, for coupling with the module laminate 108. The contact terminal 502 may extend laterally outward from the module laminate 108. [ In one embodiment, the contact terminal 502 is electrically connected to the electrical conductor 208 in the laminate structure of the module laminate 108. Alternatively, the electrical conductor 208 may extend outward from the side edge 206 to connect to the contact base portion 602. Thus, the contacts 308 can transfer current from the PV cell 110 to the outside connection point laterally outward.

Referring to Figure 10, a cross-sectional view of a module frame with a plug receptacle mounted on a module laminate in accordance with one embodiment of the present application is shown. The module frame 802 may be mounted on the contact portion 308 mounted along the side edge 206. For example, the plug receptacle 302 of the external electrical connector 300 may include a mounting casing 1002 for attachment to the side edge 206. More specifically, the mounting casing 1002 can be integrated into the module frame 802 and can have a size and shape that can be clicked into a predetermined position around the contact base portion 602. That is, the mounting casing 1002 may have a U-shaped cross-sectional structure around the contact channel 1004, and the contact channel 1004 may be sized to accommodate the contact base 602 of the contact 308. In one embodiment, a filler, such as a silicone-based adhesive, can be placed in the contact channel 1004 to fill the space between the mounting casing 1002 and the module laminate 108. [ The adhesive filler can secure the module frame 802 to the module laminate 108 and seal around the module laminate 108 to prevent water inflow into the contact channel 1004 and module circuitry within the panel.

The mounting casing 1002 may surround the contact channel 1004 on the opposite side of the base wall 406 from the plug channel 402 in the plug casing 306. The plug receptacle 302 can receive the contact portion terminal 502 through the contact slot 408 of the base wall 406 when the mounting casing 1002 straddles the module laminate 108. In this case, the contact base 602 can be held in the contact channel 1004 between the base wall 406 and the side edge 206 and the contact terminal 502 can be held in the plug channel 408 through the contact slot 408 402, respectively. The external electrical connector 300 is formed along the side edge 206 of the module laminate 108 by connecting the module frame 802 with the side edge 206 of the module laminate 108 on the contact portion 308. [

When the module frame 802 includes a plurality of plug receptacles 302, the connection module frame 802 with the side edges 206 is connected to a plurality of external The electrical connector 300 can be formed. That is, when the module frame 802 is clicked at a predetermined position on the side edge 206, the second plug receptacle 302 is connected to the second PV cell substring 116 via a second contact 308 electrically connected to the second PV cell substring 116 May be mounted on the module laminate 108. The second contact portion 308 may extend through the contact slot 408 in the base wall 406 of the second plug receptacle 302. Thus, the first external electrical connector 300 can be formed simultaneously with the second external electrical connector 300 in a single frame mounting operation.

Referring to Figure 11, a cross-sectional view of a plug receptacle having a mounting casing attached to a module laminate in accordance with one embodiment of the present disclosure is shown. The plug receptacle 302 includes a plug casing 306 around the plug channel 402 on the first side of the base wall 406 and a mounting casing 1002 around the contact channel 1004 on the opposite side of the base wall 406. [ . ≪ / RTI > The mounting casing 1002 is attached directly to the side edge 206 of the module laminate 108 to provide a contact channel 1004 between the module receptacle 302 and the module laminate 108. In one embodiment, Thus, the electrical conductor 208 can be routed to the contact channel 1004 through the side edge 206. The electrical conductor 208 may also be folded and protected within the contact channel 1004. As a result, the electrical conductor 208 may have sufficient length to allow the assembly to contact the contact portion 308 that is easier to perform since the contact can be folded to a lower profile after completion.

The electrical conductor 208 may be routed through the contact channel 1004 to a connection point where the contacts 308 are present. The contact portion 308 has a profile in which the contact base portion 602 extends around the side edge 206 of the module laminate 108 and the contact terminal 502 extends into the plug channel 402. In one embodiment, A portion of the contact base portion 602 may be parallel to the front layer 202 and the contact portion terminal 502 may extend upwardly from the contact base portion 602. The mounting casing 1002 may have a profile similar to the contact base portion 602. That is, the mounting casing 1002 may wrap the side edge 206 of the module laminate 108. In one embodiment, the contact base portion 602 is embedded in the mounting casing 1002. For example, the contact base portion 602 may be a metal component that is overmolded within the plastic mounting casing 1002. The mounting casing 1002 and / or the contact base 602 may thus be clipped on the side edge 206 to secure the external electrical connector 300 to the module laminate 108.

The current can be transmitted laterally outward from the PV module 102 and the contact terminal 502 can deliver current vertically upward in a forward or backward facing direction at a right angle to the lateral direction. The external electrical connector 300 may thus be mounted at any location on the PV module 102 to deliver current from one or more PV cell substrings 116 in the direction of routing, e.g., horizontal, 300 may have the form of accommodating the mating connector in a direction different from the routing direction, e.g., a vertical direction.

Referring to Figure 12, a flow diagram of a method of manufacturing a PV module with an external electrical connector, in accordance with one embodiment of the present application, is shown. In operation 1202, the PV cell 110, the electrical conductor 208 and the contact portion 308 may be connected between the front layer 202 and the back layer 204 of the PV module 102. In particular, the electrical connection between the PV cell 110, the electrical conductor 208 and the contact base 602 may be formed within the module laminate 108. Electrical connections may include physical connections between components. For example, the connecting PV cell 110, the electrical conductor 208 and the contact 308 may be formed by welding or soldering the contact base 602 to the electrical conductor 208 and / 0.0 > 208 < / RTI > However, electrical connections can be formed through physical contact of the components without welding or brazing. For example, the lamination process can apply sufficient pressure between the contact base portion 602 and the electrical conductor 208 to form an electrical connection and maintain the component in contact with the protective agent so that secondary welding is unnecessary.

In the above description, the contacts 308 may be inserted into the contacts with the electrical conductors 208 through the back sheet openings 606. Alternatively, the physical connection between the electrical conductor 208 and the contact portion 308 may be formed prior to adding the backside layer 204 to the module accumulation. For example, in operation 1204, the PV cell 110, the electrical conductor 208 and the contact portion 308 may be integrally secured and enclosed by a protective agent between the front layer 702 and the back layer 202 have. The first layer of the protective agent 702 may be laminated between the front layer 202 and the PV cell 110 and the second layer of the protective agent 702 may be an electrical conductor 208 and contact base portion 602 of the present invention. The backing layer 204 may then be installed such that a second protective agent 702 is sandwiched between the front layer 202 and the backing layer 204 such that the backing sheet openings 606 align with the contact terminal 502 have. When the protective agent 702 is squeezed between the front layer 202 and the back layer 204, it can evenly spread around the module circuit in the panel in the laminate structure. The contact base 602 may thus be sealed between the front layer 202 and the backing layer 204 and the contact terminals 502 may be connected to the exterior of the module laminate 108 via the backsheet opening 606, Lt; / RTI >

In one embodiment, the contact terminal 502 is protected during the sealing operation described above. For example, contact terminal 502 may be covered with a protector before surrounding PV cell 110, electrical conductor 208 and contact 308 with protective agent 702. For example, the protector may be an electrically insulating cap disposed over the contact terminal 502 before compressing the protector 702 between the front layer 202 and the backing layer 204. The protective cap insulates the contact terminal 502 so that the contact terminal 502 can be electrically insulated from the uncoated electrically conductive < RTI ID = 0.0 > State.

At task 1206, the protector 702 may be cured. The curing can be carried out by heat treatment or by ultraviolet irradiation of the protective agent 702. Thus, the protective agent 702 may be cured to integrally bond the laminate structure and to maintain the module circuitry, e.g., contacts 308, in the panel in electrical connection with the PV cell substring 116.

At task 1208, the plug receptacle 302 may be mounted to the backing layer 204. The plug receptacle 302 can be inserted over the contact portion 308 by passing the contact portion terminal 502 through the contact portion slot 408, for example. The base 310 of the plug receptacle 302 may be attached to the back surface 304 of the backing layer 204. Adhesive 704 may be used to form an adhesion between plug receptacle 302 and backing layer 204. That is, an adhesive 704 may be applied between the plug receptacle 302 and the backing layer 204, and the adhesive 704 may be cured to form an adhesion between the components. In the above description, the adhesive 704 may be the same material as the protective agent 702, so that the protective agent 702 may be applied and cured simultaneously with application and curing between the front layer 202 and the backing layer 204. Alternatively, the adhesive 704 may be applied and cured as a secondary operation after the module laminate 108 is formed by the lamination process. The PV module 102 having an external electrical connector 300 for receiving the external cable 106 or the mating connector of the panel external electronic device 104 can be manufactured.

As shown in Fig. 12, the work of the method of manufacturing a PV module having an electrical connector for a panel external electronic device can be performed in a different order. For example, an assembly of electrical circuit components may be performed at the front end of the process prior to performing lamination and / or curing operations.

In operation 1202, the back sheet openings 606 may be formed in the backing layer 204 to provide holes or spaces for insertion of the adhesive portions 308. [ The contact base 602 may be inserted into the backsheet opening 606 and the contacts 308 may be welded to the electrical conductor 208 or physically and electrically connected (or directly connected to the PV cell 100) Circuit can be formed.

In one embodiment, task 1208 may immediately follow task 1202, or plug receptacle 302 may be mounted to backing layer 204. In particular, the base 310 may be attached by a back surface 304, e.g., adhesive bonding. Thus, the bond portion terminal 502 can pass through the contact channel 1004 through the contact slot 408. Thus, an electrical circuit for external connection to the PV module 102 may be formed prior to completing the sealing operation during the lamination / curing operation.

In operation 1204, the PV cell 110, the electrical conductor 208 and the contact portion 308 may be integrally secured and enclosed by a protective agent between the front layer 702 and the back layer 202. The protector 702 may similarly surround a portion of the plug receptacle 302, for example, Then, at task 1206, the protective agent 702 may be cured to complete the lamination process. The cured protective agent 702 can securely bond the electrical conductor 208, the contact portion 308, the back surface layer 204, and the plug receptacle 302 integrally. Thus, the operation of FIG. 12 can be performed in various orders to fabricate the PV module 102 with external electrical connectors for panel external electronics.

The above-described method may be different from a general module manufacturing process used today. Conventional methods include forming a PV laminate having an electric ribbon passing through a hole in the back sheet or corner of the PV panel, and then attaching the junction box to the already laminated and cured PV panel using an adhesive. It will be appreciated that the advantages of the method described above relative to conventional manufacturing methods include the ability to embed modular electronics in the laminate of the PV module 102. For example, a DC optimizer having the size of a small microchip may be embedded within the PV module 102 or mounted on the PV module 102 and connected to the electrical conductor 208 during the manufacturing process. The built-in or mounted electronics on the panel can be performed before the lamination / curing operation.

13, a cross-sectional perspective view of an external electrical connector of a photovoltaic module according to an embodiment of the present invention is shown. The external electrical connector 300 may include a contact portion 308 that holds the plug receptacle 302. More specifically, the contact portion 308, which may be bonded to the module laminate 108 as described above, may secure the plug receptacle 302 in a position relative to the module laminate 108 of the PV module 102 . The components of the external electrical connector 300 having self-retaining features may be similar to those described above. For example, the plug receptacle 302 extends from the base 310 to form a base 310 mounted on the module laminate 108 (not shown) and a plug channel 402 for receiving an external plug And may include a plug casing 306. The contact portion 308 may also include a contact portion terminal 502 extending from the contact portion base 602. The contact base 602 may be attached to an electrical conductor 208 (not shown) within the module laminate 108 and the contact terminal 502 may be attached to the plug channel 604 along the contact channel 604, (Not shown). In one embodiment, at least a portion of the contact base portion 602 may be held between the front layer 202 and the back layer 204 so that retention can be applied to the contact portion 502. In particular, the contact portion 502 may resist removal from the module laminate 108, for example, when a plug attached to the external cable 106 is pulled out of the external electrical connector 300.

In one embodiment, the contact terminal 502 can deliver retention to the plug receptacle 302. For example, contact terminal 502 may include one or more retention tabs 1302 extending laterally from contact axis 604 and disposed over base wall 406. For example, when a plug of the outer cable 106 applies a frictional removal force to the plug casing 306, the base wall 406 is held by the retaining tab (s) 1302 when a removal force is applied to the plug receptacle 302. [ The retaining tab (s) 1302 may press down on the base wall 406 to retain the plug receptacle 302 against the module laminate 108. As shown in Fig. Thus, the in-laminate abutment 308 can lock down the housing provided by the plug receptacle 302 downwardly.

The holding tab 1302 can be bent inward from the holding state shown in Fig. 13 to an insertion / removal state (not shown). The retaining tab 1302 may be bent laterally inward toward the contact axis 604 until the distance between the tips of the retaining tab 1302 is less than the width of the contact slot 408. [ The retaining tab 1302 slides the contact slot 408 over the contact terminal 502 to move the retaining tab 1302 between the retention state and the insertion / removal state so that the plug receptacle 302 contacts the contact terminal 502 To be mounted on or removed from the upper module laminate 108.

The retaining tab 1302 of FIG. 13 represents a retention feature that can be incorporated into the contact portion 308 to retain the plug receptacle 302. That is, the holding tab 1302 is illustrative and not restrictive. Alternative retention features can be considered. For example, contact terminal 502 may include a cylindrical core, and the threaded feature may revolve around the core to provide a threaded fastener feature. The contact slot 408 may have a mating threaded surface such that the plug receptacle 302 is threaded onto the contact terminal 502 and held against the module laminate 108. [ Accordingly, many alternative arrangements of the external electrical connector 300 can be considered within the scope of this description.

The retention tab 1302 can be conductive or nonconductive and can be integrated into or separate from the contact terminal 502. For example, contact terminal 502 and retention tab 1302 may be fabricated as discrete portions of a monolithically conductive form, for example, a metal shim cut and bent into a desired shape, May be conductive. Alternatively, the contact terminal 502 can be made of an electrically conductive material, and the retaining tab 1302 can be made of a polymeric insulating material. The retaining tab 1302 can be overmolded on the contact terminal 502. [ Thus, the retention tab may be made of a material selected for flexibility and / or elasticity to perform the retention function, and the contact terminal 502 may be made of a material selected for electrical conductivity to perform the electrical connection function .

Retention features of the external electrical connector 300 may penetrate the backing layer 204 of the module laminate 108. For example, retention tab 1302 may extend through openings formed in backing layer 204 and may be laminated within module laminate 108. The retention force can be transferred from the module laminate 108 to the plug receptacle 302 via the contact feature terminal portion 502 and retention feature attached to the contact base portion 602. [

PV modules with external electrical connectors have been described. Although specific implementations have been described above, even if only one implementation is described for a particular feature, these implementations are not intended to limit the scope of the present invention. Examples of the features provided in this disclosure are intended to be illustrative rather than restrictive unless otherwise stated. As will be apparent to those skilled in the art having the benefit of this disclosure, the foregoing description is intended to cover such alternatives, modifications, and equivalents.

The scope of the present disclosure is to be accorded the broadest interpretation so as to encompass any feature or combination of features disclosed herein (whether explicitly or implicitly), or any of their Lt; / RTI > Accordingly, new claims may be made for any combination of these features during the proceedings of the present application (or an application claiming priority thereto). In particular, it should be understood that, in the context of the appended claims, the features from the dependent claim can be combined with the features of the independent claim, and the features from each independent claim are not merely the specific combinations listed in the appended claims, . ≪ / RTI >

Claims (20)

As a photovoltaic module,
A module laminate comprising a photovoltaic cell electrically connected to an electrical conductor between a front layer and a backplane;
A plug receptacle mounted on the module laminate and including a plug casing having a plug casing around the plug channel and a contact slot aligned with the plug channel; And
A contact portion attached to the electrical conductor and a contact portion extending into the plug channel through the contact slot. The photovoltaic module according to claim 1, wherein the contact terminal has terminal rigidity with respect to the contact axis, the electrical conductor has a conductor stiffness around the conductor axis, and the terminal stiffness is greater than the conductor stiffness. 3. The photovoltaic module of claim 2, wherein the contact terminal includes a contact cross-sectional area, the contact slot comprises a slot cross-sectional area, and the contact cross-sectional area is smaller than the slot cross-sectional area. 4. The photovoltaic module of claim 3, wherein the plug receptacle is mounted on the back surface of the backing layer, the contact base is parallel to the back surface, and the contact terminals are perpendicular to the back surface. 5. The method of claim 4,
A protective agent surrounding the contact base between the front layer and the back layer; And
A photovoltaic module, further comprising an adhesive between the plug receptacle and the module laminate. 4. The photovoltaic module of claim 3, wherein the module laminate comprises a side edge and the plug receptacle is mounted on a side edge.  7. The photovoltaic module of claim 6 wherein the plug receptacle includes a mounting casing attached to the side edge and the mounting casing surrounds a contact channel on opposite sides of the base wall from the plug channel and the contact base is in the contact channel. 2. The module laminate of claim 1, wherein the modular laminate comprises a first substring of photovoltaic cells comprising a first photovoltaic cell and a second substring of photovoltaic cells comprising a second photovoltaic cell, And a second contact portion electrically connected and extending through the second plug receptacle. 9. The module of claim 8, further comprising a module frame mounted along a side edge of the module laminate, wherein the module frame includes a plug receptacle and a second plug receptacle, Lt; / RTI > module. As a photovoltaic system,
A photovoltaic module comprising:
A module laminate comprising a photovoltaic cell electrically connected to an electrical conductor between a front layer and a backplane,
A plug receptacle including a plug casing around the plug channel, the plug receptacle mounted on the module laminate, and
A photovoltaic module comprising a contact portion including a contact portion terminal extending into the plug channel and a contact base portion attached to the electrical conductor;
Electronic devices outside the panel; And
And an external cable extending between and electrically connecting the contact portion and the panel external electronic device. 11. The photovoltaic system of claim 10, wherein the plug receptacle includes a base wall having a contact slot aligned with the plug channel, the contact terminal extending through the contact slot to the plug channel. 12. The photovoltaic system of claim 11, wherein the plug receptacle is mounted on the back surface of the backing layer, the abutment base is parallel to the back surface, and the abutment terminal is perpendicular to the back surface. 13. The method of claim 12,
A protective agent surrounding the contact base between the front layer and the back layer; And
Further comprising an adhesive between the plug receptacle and the module laminate. 11. The module laminate of claim 10 wherein the modular laminate comprises a first substring of photovoltaic cells comprising a first photovoltaic cell and a second substring of photovoltaic cells comprising a second photovoltaic cell, And a second contact portion electrically connected and extending through the second plug receptacle. 15. The module of claim 14, further comprising a module frame mounted along a side edge of the module laminate, wherein the module frame includes a plug receptacle and a second plug receptacle, Lt; / RTI > 11. The photovoltaic system of claim 10, wherein the panel external electronics comprises one or more bypass diodes, a microinverter or a DC optimizer. As a method,
Connecting the photovoltaic cell, the electrical conductor and the contact portion between the front layer and the backing layer, wherein the contact portion includes a contact portion terminal extending between the front layer and the backing layer and outwardly through the backing layer;
Surrounding the photovoltaic cell, the electrical conductor and the contacts with a protective agent between the front layer and the back layer;
Curing the protective agent; And
Attaching a plug receptacle having a contact slot to the backing layer, the contact portion terminal extending through the contact slot. 18. The method of claim 17,
Further comprising the step of covering the contact terminals with a protector before surrounding the photovoltaic, electrical conductors and contacts with a protective agent. 18. The method of claim 17, wherein attaching the plug receptacle comprises applying an adhesive between the plug receptacle and the backing layer. 20. The method of claim 19, wherein connecting the photovoltaic cell, the electrical conductor and the contact comprises welding the contact base to the electrical conductor.

Images